Member for engaging and connecting sheets, sheets having said member, molded article using said member and process for producing said molded article

ABSTRACT

To provide a member for engaging and connecting sheets which is well suited for inserting sheets into a recess on the surface of a molded resin article such as a cushioning molded article for seats; a molded article covered with sheets by using the member for engaging and connecting sheets; and a process for producing the molded article. A member for engaging and connecting sheets, comprising a fixing portion which fixes sheets, an engaging portion and a linking portion which links the fixing portion and the engaging portion wherein a number of engaging elements are installed on outer surface of the engaging portion; sheets which is linked with the member; and a process for producing a molded article which comprises inserting sheets into a recess on the surface of a molded article, engaging the sheets with a fastener tape embedded at the bottom of the recess, covering the surface of the molded article with the sheets, and fixing the sheets thereto.

TECHNICAL FIELD

The present invention relates to a member for engaging and connecting sheets, sheets having the aforesaid member, a molded article using the aforesaid member and a process for producing the aforesaid molded article. More particularly, it is concerned with a member for engaging and connecting sheets to easily and favorably cover the surface of a cushion of molded resin article such as an automobile seat with a covering body (sheet cover) and to fix the same, a high quality sheet-covered molded article equipped with the aforesaid member and a process for producing the above-mentioned molded article.

BACKGROUND ART

Automobile seats, business chairs and backrests have heretofore been constituted by covering the surface of a cushion made of molded synthetic resin foam such as polyurethane foam with a covering body such as a sheet cover. In the case where the molded resin article is covered with the covering body, in order to prevent a space from being formed between the molded resin article and the covering body and to prevent the covering body from being brought to unfixed state, an engaging member is set up on each of the molded resin article and the covering body, thereby fixing the covering body to the molded resin article by engaging the fastening members with each other.

As a molding method for an automobile seat, there is proposed a so called Mold-In method which comprises placing, at a prescribed position inside of a mold, a fastening member having a number of engaging elements on its surface, namely a fastener tape; and pouring a molding resin into the mold to allow the resin to foam and to carry out molding so that the molded resin article and fastener tape are integrated with each other and at the same time, the engaging elements are exposed on the surface of the article. In addition, there is set up on the back surface of the covering body, engaging elements which are capable of mutually engaging with the engaging elements of the fastener tape, and by allowing the above-mentioned two-kinds of engaging elements to engage with each other, the covering body is placed over the molded resin article so as to cover the same.

There is publicly well known a method wherein a recess or a groove is provided on the molded resin article, and also a fastener tape for engagement is fixedly set up on the bottom of the recess (for instance, U.S. Pat. No. No. 5,236,243 and Japanese Patent Application Laid-Open No. 280956/1996 (Heisei 8).

U.S. Pat. No. 5,236,243 describes the advantages that an expensive loop fastener tape is not in use for the cover body and besides, and forming of a connecting end portion and thread sewing for loops can be performed at the same time. In this methods, in order to insert the covering body into a narrow recess, it is cut and superimposed to make and form a selvage end, and thread lines are loosely sewn onto the surfaces of the selvage end to form loop engaging elements. However, the production of such intricate end portion gives rise to a problem of a production cost equal to or higher than that of the loop fastener tape.

In addition, Japanese Patent Application Laid-Open No. 280956/1996 describes a vehicle sheet in which production work can be simplified, since linking is necessarily intensified by pushing pressure when a driver is seated, strict accuracy is not needed on a setting position of fastener tapes. The sheet has a cover body made by forming loop engaging elements on the outer surface of a tube-like soft textile such as towel textile, inserting the soft textile into a recess of a molded article, and engaging the same with hook engaging elements installed on the bottom of the recess to fix a covering body on the molded article. Nevertheless, it is difficult to insert the tube-like end portion made of soft textile into a narrow recess, thereby bringing about a disadvantage of decrease in working efficiency.

Such being the case, an industrially satisfactory method is not yet available, whereby improvement thereon has been sought.

The present invention has been made in the light of the above-mentioned problems. Thus an object of the present invention is to provide a member for engaging and connecting sheets which is well suited for inserting a covering body such as a sheet cover into the recess of a molded article such as an automobile seat, and easily and favorably covering the molded article with a covering body and fix the same; a molded article easily producible by the use of the above-mentioned member for engaging and connecting; and further a process for producing the molded article.

DISCLOSURE OF THE INVENTION

It has been found by the present inventors that the objects can be achieved by applying a member for engaging and connecting having a specific constitution.

Specifically, the present invention provides the followings.

-   -   1. A member for engaging and connecting sheets which comprises a         fixing portion which fixes sheets, an engaging portion and a         linking portion which links said fixing portion and said         engaging portion wherein a number of engaging elements are         installed on outer surface of said engaging portion;     -   2. The member for engaging and connecting sheets as set forth in         item 1 wherein said member is composed of a synthetic resin;     -   3. The member for engaging and connecting sheets as set forth in         item 1 or 2 wherein said engaging portion is arranged almost         perpendicular to the axis of said fixing portion;     -   4. The member for engaging and connecting sheets as set forth in         item 1 or 2 wherein the engaging elements of said engaging         portion is constituted by integral molding of the fixing portion         and the linking portion;     -   5. The member for engaging and connecting sheets as set forth in         item 1 or 2 wherein the engaging elements of said engaging         portion is installed on the outer surface of said engaging         portion by means of adhesion or hot-melt bonding;     -   6. The member for engaging and connecting sheets as set forth in         item 1 or 2 wherein the linking portion has a linear, curved or         arc cross sectional shape;     -   7. The member for engaging and connecting sheets as set forth in         item 1 or 2 wherein the fixing portion and the linking portion         have each an almost linear cross sectional shape, and the         engaging portion abuts almost perpendicular to the linking         portion;     -   8. Sheets with a member for engaging and connecting sheets         characterized in that the member which comprises a fixing         portion, an engaging portion and a linking portion which links         said fixing portion and said engaging portion wherein the         engaging elements are installed on outer surface of said         engaging portion and ends of the sheets are fixed together by         the fixing portion of said member;     -   9. A molded article covered with sheets that are engaged and         connected to a recess on said molded article, characterized in         that a member for engaging and connecting sheets which comprises         a fixing portion, an engaging portion and a linking portion         which links said fixing portion and said engaging portion         wherein a number of engaging elements are installed on outer         surface of said engaging portion and ends of the sheets are         fixed to each other by the fixing portion of said member, and         said engaging elements of the engaging portion are engaged with         engaging elements of a fastener tape which is fixedly embedded         in the recess on said molded article;     -   10. The molded article as set forth in item claim 9 wherein said         engaging elements of the member are loop-like engaging elements,         the engaging elements of a fastener tape on the bottom of the         recess are hook-like engaging elements, and the molded article         is made of a foamed synthetic resin;     -   11. A process for producing a molded article, comprising         inserting sheets with a member for engaging and connecting         sheets into a recess which is concavely provided on said molded         article, engaging and connecting the sheets with the molded         article, and covering the molded article therewith, wherein said         member for engaging and connecting sheets comprises a fixing         portion, an engaging portion and a linking portion which links         said fixing portion and said engaging portion; a number of         engaging elements are installed on outer surface of said         engaging portion of said member; and ends of each of the sheets         are fixed to each other by the fixing portion of said member;         and     -   12. The process for producing a molded article as set forth in         item 11, comprising fixedly embedding a fastener tape having a         number of engaging elements on the bottom of the recess on the         molded article, and engaging said engaging elements of the         fastener tape with the engaging elements which are installed on         outer surface of the engaging portion of said member for         engaging and connecting the sheets.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective view showing a conventional sheet for covering a molded article and a method for inserting the sheet into the recess on the molded article;

FIG. 2-1 is a schematic perspective view showing a sheet for covering a molded article according to the present invention and a method for inserting the sheet into the recess on the molded article; and

FIG. 2-2 through FIG. 2-8 are cross sectional views showing other member for engaging and connecting sheets according to the present invention.

The symbols in the drawings shall have the following designations.

1, 2: sheet, 3: end of sheet, 4: fastener tape, 5: engaging elements (loops), 6: molded resin article, 7: recess, 8: bottom portion of the recess, 9: engaging elements of a fastener tape (hooks), 10: fastener tape, 11: fixing portion, 12: linking portion, 13: engaging portion, 14: rod (core body).

THE MOST PREFERRED EMBODIMENT TO CARRY OUT THE INVENTION

In the following, the present invention will be described with reference to the attached drawings.

FIG. 1 is a schematic view illustrating a conventional covering sheet for a molded article and a method for inserting the covering sheet into a recess on the molded article. The end 3 of each of the covering sheet 1, 2 is arranged so as to be enveloped with a fastener tape 4, and sewn together to form a engaging end. On the outer surface of the fastener tape 4, there are installed a large number of engaging elements, for instance, loop-like elements.

There is fixedly embedded a fastener tape 10 having a large number of engaging elements 9 on the bottom portion 8 of the recess 7 which is concavely provided on a surface of the molded resin article 6 composed of a foamed synthetic resin. In the case of the recess 7 having a large space, it is easy to insert the end 3 of sheets through the recess 7 and engage the engaging elements 5 and engaging elements 9 of a fastener tape 10 with each other, but in the case of a small space, it becomes difficult to insert the end 3 of sheets to the recess owing to the sheet being flexible and strong resistance between the sheet and the resin, thereby making it difficult to engage both of the above-mentioned elements. In particular, in the case where a variety of products are manufactured in an industrial scale, easy and reliable working is required, whereby the conventional technique has been far from satisfactory.

FIG. 2-1 is a schematic perspective view which describes the covering sheets for a molded article and also a method for inserting the covering sheets into the recess on the molded article according to the present invention. The member for engaging and connecting sheets according to the present invention is used by being linked with the end of a sheets 1 and 2. Examples of the sheets 1 and 2 include not only knitted or moven fabric, but also nonwoven fabric composed of natural fiber or synthetic fiber, foamed synthetic resin sheet such as foamed polyethylene sheet and foamed polystyrene sheet, leather sheet, laminates thereof and composite materials. It is possible to properly optionally select the sheets from a wide range of materials according to the purpose of use of the molded article and other factors. In order to insert the sheets 1 and 2 into a small recess which is concavely provided on the molded resin article 6, the sheets can be fixed by putting both the ends of the sheets in order, aligning the fixing portion 11 of the member for engaging and connecting between the two ends or outside thereof (not shown on the drawing), and subjecting the portion to any one of sewing, adhesion by the use of an adhesive, hot-melt adhesion by means of heat, light, ultrasonic wave, high frequency electric wave treatments or the like.

The member for engaging and connecting sheets as illustrated on FIG. 2-1 is constituted of a fixing portion 11 in the form of filament or band, an engaging portion 13 which is equipped on the outer surface with a large number of engaging elements 5 and a linking portion 12 which links the aforesaid portions 11 and 13. The member for engaging and connecting, which is inserted into the long recess 7 of the molded article, is in the form of a long tape as a whole. The specific length thereof, which is determined according to necessity, is usually in the range of 10 cm to 1 m, approximately. In order that the engaging elements 5 which are installed on the engaging portion 13 have to be efficiently engaged with the engaging elements 9 of the fastener tape 10 which is fixedly installed on the bottom portion 8 of the recess 7 on the molded article, it is preferable that the engaging portion 13 should be plane and accordingly be arranged almost perpendicular to the face or axis of the fixing portion 11. The term “perpendicular” need not be strict, but needs only to be in such relation that the engaging elements are sufficiently engaged with the engaging elements on the bottom portion. Saying it differently, it needs only that one face of the engaging elements is almost opposite to the other face of the engaging elements.

FIGS. 2-2 through 2-7 are cross sectional views showing various constructions of the member for engaging and connecting sheets according to the present invention. With regard to FIG. 2-2, the cross sectional shapes of the fixing portion 11 and the linking portion 12 are almost continuous linear, and the engaging portion 13 is installed so as to abut almost perpendicular to the linking portion 12. The above-mentioned construction is easy to produce, and thus is suitably utilizable for a member of compact molded articles. FIG. 2-3 illustrates an example in which the configuration of the linking portion 12 with the engaging portion 13 is in the form of the letter “L”. The aforesaid construction exhibits improved working effect of facilitating insertion work as compared with that in FIG. 2-2, since the linking portion 12 and a supplemental portion 13′ for the engaging portion, which exist on either side of the portion 13, function as auxiliary materials for insertion into the recess. With regard to FIG. 2-4, the linking member has the linking portion 12 and a supplemental portion 13′ for the engaging portion 13 both in the form of curve in cross sectional shape, and the shape of these curves further facilitates easy introduction into the recess.

In regard to FIGS. 2-5 through 2-7, the members for engaging and connecting sheets are each of such construction as having a linking portion and engaging portion of various shapes. In regard to FIG. 2-5, there are installed a linking portion 12 having a cross sectional shape of bellmouth and an engaging portion 13 on its underside. FIG. 2-6 is of such construction as including a linking portion 12 having a circular cross sectional shape and an engaging portion 13 on the underside thereof. As illustrated on 2-6, the engaging elements 5 and the engaging elements 9 of the fastener tape 10 need to be constituted so as to be sufficiently engaged with each other even when the bottom portion of the engaging portion is in the form of circular arc. FIG. 2-7 is of such construction as including a linking portion 12 having a triangular cross sectional shape and an engaging portion 13 on the underside thereof.

In these constructions, the enclosed cross sectional portion may be a hollow pipe composed of a flexible resin, or a resinous body composed of a flexible resin or a foamed resin. Examples of usable flexible resin include various flexible polyolefin resin, polyester resin and elastomers. Examples of usable foamed resin include polyethylene foam, polystyrene foam and polyurethane foam. In addition, a metallic hollow pipe is also usable when necessary.

The engaging elements to be installed on outer surface of the engaging portion are preferably constituted by means of integral molding of the member for engaging and connecting by any of various molding methods. As a molding method, injection molding, profile extrusion molding and the like are applicable to the production. It is also possible to install the engaging elements by bonding a separately prepared member for engaging elements to the engaging portion by a usual adhesive bonding means or hot-melt bonding means. Moreover, taking into consideration stitch work with a covering body, a fibrous member can be attached on the fixing portion made of a synthetic resin.

FIG. 2-8 is a cross sectional view showing another example of the member for engaging and connecting sheets according to the present invention, wherein its construction is such that a rod 14 is wrapped by fibrous fabric or nonwoven fabric, the upper portion thereof is bonded by means of sewing, adhesive bonding, hot-melt bonding or the like to form the the fixing portion 11, the engaging portion 13 is formed on the lower side thereof, and the linking portion 12 is formed in the middle thereof. The above-mentioned construction is advantageous in that various members for engaging and connecting sheets can easily be provided by altering the combination of the rod with the fibrous fabric or nonwoven fabric.

The material for the rod is preferably a synthetic resin. In particular, the use of a flexible resin or a foamed resin brings about a member rich in flexibility, which leads to a preferable member for engaging and connecting sheets to be inserted into a curved recess. As the synthetic resin to be used for the rod, the resins same as those of the member for engaging and connecting sheets exemplified hereunder are usable. Of those are particularly preferable foamed synthetic resin such as polyethylene foam, polystyrene foam and polyurethane foam.

As the engaging elements to be installed on the member for engaging and connecting sheets according to the present invention, there are utilizable hook-shaped engaging elements and loop-shaped engaging elements. As the hook-shaped engaging elements, there are applicable those imparted with a engaging function such as the form of hook, mushroom and arrow-head. As the loop-shaped engaging elements, there are applicable knitted woven fabric with multi-filament loops, looped fabric, napped nonwoven fabric and the like. In order to avoid a fear of a hook engaging elements exposed to the outside being unnecessarily engaging with different fibrous product at the time of inserting the engaging portion into the recess 7, a loop engaging elements are preferably installed to the engaging portion. In the case of employing a loop engaging elements as the ellements, the engaging elements 9 of the fastener tape 10 which is fixedly embedded at the bottom portion 8 of the recess 7 of the molded article are invariably hook engaging elements.

The cross sectional shape of the member for engaging and connecting sheets according to the present invention can be altered to a shape other than those as illustrated hereinbefore such as polygon and zig-zag shape according to the shape of recess in the molded article and the purpose of use thereof.

The material for the member for engaging and connecting sheets according to the present invention is preferably a synthetic resin in consideration of its being bonded to the covering body. In particular, being rich in flexibility, a member made of a flexible resin or a foamed resin preferably functions as a connecting member to be inserted into the curved recess. Any synthetic resin is usable without specific limitation provided that it is imparted with sufficient mechanical strength and heat resistance. Such synthetic resin is exemplified by polyolefinic resins such as polyethylene, polypropylene, ethylene/propylene copolymer; polyester resin such as polyethylene terephthalate and polybutylene terephthalate; and polyamide resin such as 6-nylon and 6,6-nylon. Of these polyolefinic resins are particularly preferable. Moreover, taking into consideration the recycling of the member, the material therefor is preferably of the same type as that of the covering sheet. When necessary a metal is usable as a part of the member for engaging and connecting sheets.

In the present invention, the end 3 of the sheets equipped with the member for engaging and connecting sheets which is prepared in the aforesaid manner is inserted into the recess 7 which is concavely provided on the surface of the molded article, thereby being engaged and fixed on the molded article, and the surfaces of the molded article is covered with the sheet. The engaging elements 5 of the engaging portion 13 linked with the end 3 of the sheet, when engaged with the engaging elements 9 of the fastener tape 10 which is fixedly embedded on the bottom portion 8 of the recess, can certainly fix the sheet onto the surfaces of the molded article. Although the force of engagement between the engaging elements of two portions is sufficiently strong, in order to allow the frictional resistance between the sheet and the wall face of the recess to contribute to the prevention of the sheet escaping from the molded article, it is preferable that the thickness of the end of the sheet be larger than the recess and that the sheet be forcibly pushed into the recess.

A particularly preferable embodiment of the member for engaging and connecting sheets according to the present invention is that which is produced from a thermoplastic resin such as polypropylene in the shape of letter “L” as shown on FIG. 2-3, and napped nonwoven fabric is adhered to the engaging portion 13 thereof. The member for engaging and connecting sheets is hot-melt bonded to the end 3 of the sheet as illustrated on FIG. 2-1, and the resultant bonded sheet is inserted into the recess 7 on the molded resin article 6. The member for engaging and connecting sheets, which is producible at a low cost and imparted with proper flexibility, can easily be inserted into a narrow recess. Moreover, a supplemental portion 13′ which installed on an end portion of the engaging portion 13 decreases the resistance caught by the recess. Thus it is made possible to easily and certainly insert the member for engaging and connecting sheets into the recess by preparing in advance, said memeber having a corresponding shape to an intricately shaped recess.

Being constituted in the above-mentioned manner, the member for engaging and connecting sheets according to the present invention is imparted with both appropriate strength and flexibility. Accordingly in the case where the member is inserted into the recess on the molded article, the member can be pushed thereinto in a state of being moderately curved by using an insertion tool or worker's fingers, thereby enabling the inserting work to be easily and simply carried out.

The molded article to be produced according to the present invention, which is not specifically limited, is suitably applicable to sheet cushions for vehicles such as automobiles.

Industrial Applicability

According to the present invention, there is provided a member for engaging and connecting sheets which is capable of easily and favorably covering the surface of a molded resin article including not only an automobile sheet but also a cushioning molded article such as a business chair and backrest with a covering body and fixing the same. By the use of the aforesaid member for engaging and connecting, it is possible to provide a high quality sheet-covered molded article and further industrially advantageous effect is exhibited in that the production process of automobile seats or the like can be simplified. 

1. A member for engaging and connecting sheets which comprises a fixing portion which fixes sheets, an engaging portion and a linking portion which links said fixing portion and said engaging portion wherein a number of engaging elements are installed on outer surface of said engaging portion.
 2. The member for engaging and connecting sheets according to claim 1 wherein said member is composed of a synthetic resin.
 3. The member for engaging and connecting sheets according to claim 1 or 2 wherein said engaging portion is arranged almost perpendicular to the axis of said fixing portion.
 4. The member for engaging and connecting sheets according to claim 1 or 2 wherein the engaging elements of said engaging portion is constituted by integral molding of the fixing portion and the linking portion.
 5. The member for engaging and connecting sheets according to claim 1 or 2 wherein the engaging elements of said engaging portion is installed on the outer surface of said engaging portion by means of adhesion or hot-melt bonding.
 6. The member for engaging and connecting sheets according to claim 1 or 2 wherein the linking portion has a linear, curved or arc cross sectional shape.
 7. The member for engaging and connecting sheets according to claim 1 or 2 wherein the fixing portion and the linking portion have each an almost linear cross sectional shape, and the engaging portion abuts almost perpendicular to the linking portion.
 8. Sheets with a member for engaging and connecting sheets characterized in that the member which comprises a fixing portion, an engaging portion and a linking portion which links said fixing portion and said engaging portion wherein the engaging elements are installed on outer surface of said engaging portion and ends of the sheets are fixed together by the fixing portion of said member.
 9. A molded article covered with sheets that are engaged and connected to a recess on said molded article, characterized in that a member for engaging and connecting sheets which comprises a fixing portion, an engaging portion and a linking portion which links said fixing portion and said engaging portion wherein a number of engaging elements are installed on outer surface of said engaging portion and ends of the sheets are fixed to each other by the fixing portion of said member, and said engaging elements of the engaging portion are engaged with engaging elements of a fastener tape which is fixedly embedded in the recess on said molded article.
 10. The molded article according to claim 9 wherein said engaging elements of the member are loop-like engaging elements, the engaging elements of a fastener tape on the bottom of the recess are hook-like engaging elements, and the molded article is made of a foamed synthetic resin.
 11. A process for producing a molded article, comprising inserting sheets with a member for engaging and connecting sheets into a recess which is concavely provided on said molded article, engaging and connecting the sheets with the molded article, and covering the molded article therewith, wherein said member for engaging and connecting sheets comprises a fixing portion, an engaging portion and a linking portion which links said fixing portion and said engaging portion; a number of engaging elements are installed on outer surface of said engaging portion of said member; and ends of each of the sheets are fixed to each other by the fixing portion of said member.
 12. The process for producing a molded article according to claim 11, comprising fixedly embedding a fastener tape having a number of engaging elements on the bottom of the recess on the molded article, and engaging said engaging elements of the fastener tape with the engaging elements which are installed on outer surface of the engaging portion of said member for engaging and connecting the sheets. 